Catalytic Performance of Pd/Co3O4 on SiC and ZrO2 Open Cell Foams for Process Intensification of Methane Combustion in Lean Conditions

Recent Advances in Co3O4-Based Composites: Synthesis and Application in Combustion of Methane

In recent years, it has been found that adjusting the organizational structure of Co₃O₄ through solid solution and other methods can effectively improve its catalytic performance for the oxidation of low concentration methane. Its catalytic activity is close to that of metal Pd, which is expected to replace costly noble metal catalysts. Therefore, the in-depth research on the mechanism and methods of Co₃O₄ microstructure regulation has very important academic value and economic benefits. In this paper, we reviewed the catalytic oxidation mechanism, microstructure regulation mechanism, and methods of nano-Co₃O₄ on methane gas, which provides reference for the development of high-activity Co₃O₄-based methane combustion catalysts. Through literature investigation, it is found that the surface energy state of nano-Co₃O₄ can be adjusted by loading of noble metals, resulting in the reduction of Co-O bond strength, thus accelerating the formation of reactive oxygen species chemical bonds, and improving its catalytic effect. Secondly, the use of metal oxides and non-metallic oxide carriers helps to disperse and stabilize cobalt ions, improve the structural elasticity of Co₃O₄, and ultimately improve its catalytic performance. In addition, the performance of the catalyst can be improved by adjusting the microstructure of the composite catalyst and optimizing the preparation process. In this review, we summarize the catalytic mechanism and microstructure regulation of nano-Co₃O₄ and its composite catalysts (embedded with noble metals or combined with metallic and nonmetallic oxides) for methane combustion. Notably, this review delves into the substance of measures that can be used to improve the catalytic performance of Co₃O₄, highlighting the constructive role of components in composite catalysts that can improve the catalytic capacity of Co₃O₄. Firstly, the research status of Co₃O₄ composite catalyst is reviewed in this paper. It is hoped that relevant researchers can get inspiration from this paper and develop high-activity Co₃O₄-based methane combustion catalyst.

Bulk Co3O4 for Methane Oxidation: Effect of the Synthesis Route on Physico-Chemical Properties and Catalytic Performance

The synthesis of bulk pure Co3O4 catalysts by different routes has been examined in order to obtain highly active catalysts for lean methane combustion. Thus, eight synthesis methodologies, which were selected based on their relatively low complexity and easiness for scale-up, were evaluated. The investigated procedures were direct calcination of two different cobalt precursors (cobalt nitrate and cobalt hydroxycarbonate), basic grinding route, two basic precipitation routes with ammonium carbonate and sodium carbonate, precipitation-oxidation, solution combustion synthesis and sol-gel complexation. A commercial Co3O4 was also used as a reference. Among the several examined methodologies, direct calcination of cobalt hydroxycarbonate (HC sample), basic grinding (GB sample) and basic precipitation employing sodium carbonate as the precipitating agent (CC sample) produced bulk catalysts with fairly good textural and structural properties, and remarkable redox properties, which were found to be crucial for their good performance in the oxidation of methane. All catalysts attained full conversion and 100% selectivity towards CO2 formation at a temperature of 600 °C while operating at 60,000 h−1. Among these, the CC catalyst was the only one that achieved a specific reaction rate higher than that of the reference commercial Co3O4 catalyst.

Porous Silicon Carbide (SiC): A Chance for Improving Catalysts or Just Another Active-Phase Carrier?

There is an obvious gap between efforts dedicated to the control of chemicophysical and morphological properties of catalyst active phases and the attention paid to the search of new materials to be employed as functional carriers in the upgrading of heterogeneous catalysts. Economic constraints and common habits in preparing heterogeneous catalysts have narrowed the selection of active-phase carriers to a handful of materials: oxide-based ceramics (e.g. Al₂O₃, SiO₂, TiO₂, and aluminosilicates-zeolites) and carbon. However, these carriers occasionally face chemicophysical constraints that limit their application in catalysis. For instance, oxides are easily corroded by acids or bases, and carbon is not resistant to oxidation. Therefore, these carriers cannot be recycled. Moreover, the poor thermal conductivity of metal oxide carriers often translates into permanent alterations of the catalyst active sites (i.e. metal active-phase sintering) that compromise the catalyst performance and its lifetime on run. Therefore, the development of new carriers for the design and synthesis of advanced functional catalytic materials and processes is an urgent priority for the heterogeneous catalysis of the future. Silicon carbide (SiC) is a non-oxide semiconductor with unique chemicophysical properties that make it highly attractive in several branches of catalysis. Accordingly, the past decade has witnessed a large increase of reports dedicated to the design of SiC-based catalysts, also in light of a steadily growing portfolio of porous SiC materials covering a wide range of well-controlled pore structure and surface properties. This review article provides a comprehensive overview on the synthesis and use of macro/mesoporous SiC materials in catalysis, stressing their unique features for the design of efficient, cost-effective, and easy to scale-up heterogeneous catalysts, outlining their success where other and more classical oxide-based supports failed. All applications of SiC in catalysis will be reviewed from the perspective of a given chemical reaction, highlighting all improvements rising from the use of SiC in terms of activity, selectivity, and process sustainability. We feel that the experienced viewpoint of SiC-based catalyst producers and end users (these authors) and their critical presentation of a comprehensive overview on the applications of SiC in catalysis will help the readership to create its own opinion on the central role of SiC for the future of heterogeneous catalysis.

Demonstration of the Influence of Specific Surface Area on Reaction Rate in Heterogeneous Catalysis

Heterogeneous catalysis plays an important role in many chemical reactions, especially those applied in industrial processes, and therefore, its theoretical foundations are introduced not only to students majoring in chemical engineering or catalysis but also as part of general chemistry courses. The consideration of catalytic activity of various solids and mechanisms of catalytic reactions requires the introduction of the concept of an active site, which together with the catalyst specific surface area are discussed as key parameters controlling the reaction rate. There are many known demonstrations of heterogeneous catalysis phenomena that can be performed live in a lecture hall, but all of them focus only on the general idea of catalytic processes and are not suitable for quantitative analysis. Therefore, herein we present a simple demonstration of the influence of the specific surface area of a catalyst on the rate of a catalytic reaction. This demonstration is based on a model reaction of hydrogen peroxide decomposition catalyzed by cobalt spinel (Co₃O₄) calcined at various temperatures. The differences in reaction rates can be monitored visually, and the obtained data can be used directly for a simple kinetic analysis, including comparison of numerical values of the reaction rate constants.

Recent advances in three-way catalysts of natural gas vehicles

This review presents recent advances in TWCs for NGVs, particularly for Pd-based catalysts and potential alternatives.

Synthesis, Characterization and Kinetic Behavior of Supported Cobalt Catalysts for Oxidative after-Treatment of Methane Lean Mixtures

The present work addresses the influence of the support on the catalytic behavior of Co₃O₄-based catalysts in the combustion of lean methane present in the exhaust gases from natural gas vehicular engines. Three different supports were selected, namely γ-alumina, magnesia and ceria and the corresponding catalysts were loaded with a nominal cobalt content of 30 wt. %. The samples were characterized by N₂ physisorption, wavelength dispersive X-ray fluorescence (WDXRF), X-ray diffraction (XRD), Raman spectroscopy, X-ray photoelectron spectroscopy (XPS) and temperature-programmed reduction with hydrogen and methane. The performance was negatively influenced by a strong cobalt-support interaction, which in turn reduced the amount of active cobalt species as Co₃O₄. Hence, when alumina or magnesia supports were employed, the formation of CoAl₂O₄ or Co-Mg mixed oxides, respectively, with a low reducibility was evident, while ceria showed a lower affinity for deposited cobalt and this remained essentially as Co₃O₄. Furthermore, the observed partial insertion of Ce into the Co₃O₄ lattice played a beneficial role in promoting the oxygen mobility at low temperatures and consequently the catalytic activity. This catalyst also exhibited a good thermal stability while the presence of water vapor in the feedstream induced a partial inhibition, which was found to be completely reversible.

Oxidative Coupling of Methane over Mn2O3-Na2WO4/SiC Catalysts

The oxidative coupling of methane (OCM) is operated at high temperatures and is a highly exothermic reaction; thus, hotspots form on the catalyst surface during reaction unless the produced heat is removed. It is crucial to control the heat formed because surface hotspots can degrade catalytic performance. Herein, we report the preparation of Mn2O3-Na2WO4/SiC catalysts using SiC, which has high thermal conductivity and good stability at high temperatures, and the catalyst was applied to the OCM. Two Mn2O3-Na2WO4/SiC catalysts were prepared by wet-impregnation on SiC supports having different particle sizes. For comparison, the Mn2O3-Na2WO4/SiO2 catalyst was also prepared by the same method. The catalysts were analyzed by nitrogen adsorption–desorption, X-ray diffraction, scanning electron microscopy, and transmission electron microscopy. The transformation of SiC into α-cristobalite was observed for the Mn2O3-Na2WO4/SiC catalysts. Because SiC was completely converted into α-cristobalite for the nano-sized SiC-supported Mn2O3-Na2WO4 catalyst, the catalytic performance for the OCM reaction of Mn2O3-Na2WO4/n-SiC was similar to that of Mn2O3-Na2WO4/SiO2. However, only the surface layer of SiC was transformed into α-cristobalite for the micro-sized SiC (m-SiC) in Mn2O3-Na2WO4/m-SiC, resulting in a SiC@α-cristobalite core–shell structure. The Mn2O3-Na2WO4/m-SiC showed higher methane conversion and C2+ yield at 800 and 850 °C than Mn2O3-Na2WO4/SiO2.

Comparative Study of the Characteristics and Activities of Pd/γ-Al2O3 Catalysts Prepared by Vortex and Incipient Wetness Methods

5 wt% Pd/γ-Al2O3 catalysts were prepared by a modified Vortex Method (5-Pd-VM) and Incipient Wetness Method (5-Pd-IWM), and characterized by various techniques (Inductively coupled plasma atomic emission spectroscopy (ICP-AES), N2-physisorption, pulse CO chemisorption, temperature programmed reduction (TPR), X-ray photoelectron spectroscopy (XPS), scanning transmission electron microscopy (STEM), and X-ray diffraction (XRD)) under identical conditions. Both catalysts had similar particle sizes and dispersions; the 5-Pd-VM catalyst had 0.5 wt% more Pd loading (4.6 wt%). The surfaces of both catalysts contained PdO and PdOx with about 7% more PdOx in 5-Pd-VM. High-angle annular dark-field scanning transmission electron microscopy (HAADF-STEM) and scanning electron microscope (SEM) images indicated presence of PdO/PdOx nanocrystals (8–10 nm) on the surface of the support. Size distribution by STEM showed presence of smaller nanoparticles (2–5 nm) in 5-Pd-VM. This catalyst was more active in the lower temperature range of 275–325 °C and converted 90% methane at 325 °C. The 5-Pd-VM catalyst was also very stable after 72-hour stability test at 350 °C showing 100% methane conversion, and was relatively resistant to steam deactivation. Hydrogen TPR of 5-Pd-VM gave a reduction peak at 325 °C indicating weaker interactions of the oxidized Pd species with the support. It is hypothesized that smaller particle sizes, uniform particle distribution, and weaker PdO/PdOx interactions with the support may contribute to the higher activity in 5-Pd-VM.

Rice Husk Derived Porous Silica as Support for Pd and CeO2 for Low Temperature Catalytic Methane Combustion

The separation of Pd and CeO2 on the inner surface of controlled porous glass (CPG, obtained from phase-separated borosilicate glass after extraction) yields long-term stable and highly active methane combustion catalysts. However, the limited availability of the CPG makes such catalysts highly expensive and limits their applicability. In this work, porous silica obtained from acid leached rice husks after calcination (RHS) was used as a sustainable, cheap and broadly available substitute for the above mentioned CPG. RHS-supported Pd-CeO2 with separated CeO2 clusters and Pd nanoparticles was fabricated via subsequent impregnation/calcination of molten cerium nitrate and different amounts of palladium nitrate solution. The Pd/CeO2/RHS catalysts were employed for the catalytic methane combustion in the temperature range of 150–500 °C under methane lean conditions (1000 ppm) in a simulated off-gas consisting of 9.0 vol% O2, and 5.5 vol% CO2 balanced with N2. Additionally, tests with 10.5 vol% H2O as co-feed were carried out. The results revealed that the RHS-supported catalysts reached the performance of the cost intensive benchmark catalyst based on CPG. The incorporation of Pd-CeO2 into RHS additionally improved water-resistance compared to solely Pd/CeO2 lowering the required temperature for methane combustion in presence of 10.5 vol% H2O to values significantly below 500 °C (T90 = 425 °C).

Synthesis of a Highly Stable Pd@CeO2 Catalyst for Methane Combustion with the Synergistic Effect of Urea and Citric Acid

Making use of synergy between urea and citric acid, a core-shell Pd@CeO₂ catalyst with spherical morphology was facilely synthesized by a hydrothermal method. The formation mechanism of the core-shell structure in the presence of citric acid and hydrogen peroxide was studied. Results showed that the Pd@CeO₂ catalyst exhibited high catalytic activity in methane oxidation. Pd nanoparticles were well stabilized by CeO₂ shell encapsulation, resulting in high stability of the catalyst. A high CH₄ conversion of 99% was retained after 50 h on-stream reaction at 500 °C. Additionally, many tiny pores on the CeO₂ shell surface were beneficial for the full contact between reactants and active components. Pd nanoparticles were highly dispersed inside the shell, improving the utilization efficiency of active components. The results also demonstrated that the Pd species in the catalyst existed in the form of oxidation state, mainly in PdO (ca. 66.6%), which played an essential part in methane combustion.